U.S. patent application number 10/255253 was filed with the patent office on 2003-06-19 for electric motor drive controller with voltage control circuit operative in different modes.
Invention is credited to Richey, Joseph B., Strothmann, Thomas.
Application Number | 20030111972 10/255253 |
Document ID | / |
Family ID | 27371326 |
Filed Date | 2003-06-19 |
United States Patent
Application |
20030111972 |
Kind Code |
A1 |
Strothmann, Thomas ; et
al. |
June 19, 2003 |
Electric motor drive controller with voltage control circuit
operative in different modes
Abstract
An electric motor drive controller for an electric vehicle
driven by a motor with permanent excitation and powered by an
energy source comprises: a power control stage coupleable to the
motor for generating a drive signal at a voltage to control the
motor at a desired speed; a voltage control circuit connectable
between the energy source and the power control stage for
controlling the voltage of the drive signal at a first voltage
potential in one operating mode and at a voltage potential greater
than the first voltage potential in another operating mode; and a
mode controller for controlling the operating modes of the voltage
control circuit based on properties of the drive signal.
Inventors: |
Strothmann, Thomas;
(Wallenhorst, DE) ; Richey, Joseph B.; (Chagrin
Falls, OH) |
Correspondence
Address: |
CALFEE HALTER & GRISWOLD, LLP
800 SUPERIOR AVENUE
SUITE 1400
CLEVELAND
OH
44114
US
|
Family ID: |
27371326 |
Appl. No.: |
10/255253 |
Filed: |
September 26, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10255253 |
Sep 26, 2002 |
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10068391 |
Feb 6, 2002 |
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60266736 |
Feb 6, 2001 |
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60354765 |
Feb 6, 2002 |
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Current U.S.
Class: |
318/268 |
Current CPC
Class: |
H02P 2201/11 20130101;
B60L 50/00 20190201; Y02T 10/642 20130101; Y02T 10/64 20130101;
H02P 2201/07 20130101; H02P 2201/09 20130101 |
Class at
Publication: |
318/268 |
International
Class: |
H02P 005/00 |
Claims
What is claimed is:
1. An electric motor drive controller for an electric vehicle
driven by a motor with permanent excitation and powered by an
energy source, said motor drive controller comprising: a power
control stage coupleable to said motor for generating a drive
signal at a voltage to control said motor at a desired speed; a
voltage control circuit connectable between said energy source and
said power control stage for controlling the voltage of said drive
signal at a first voltage potential in one operating mode and at a
voltage potential greater than the first voltage potential in
another operating mode; and a mode controller for controlling the
operating modes of said voltage control circuit based on properties
of said drive signal.
2. The motor drive controller of claim 1 wherein the power control
stage is capable of generating a maximum drive signal at the first
voltage potential to control the motor at the desired speed; and
wherein the mode controller includes a sensing circuit for
monitoring the drive signal; and a mode control circuit governed by
said sensing circuit to control the voltage control circuit between
operating modes when the drive signal is determined to be within a
predetermined range of the maximum drive signal.
3. The motor drive controller of claim 2 wherein the power control
stage includes means for generating the drive signal as a pulse
width modulated (PWM) signal at the voltage controlled by the
voltage control circuit, the duty cycle of said PWM drive signal
being a measure thereof; and wherein the sensing circuit is
operative to monitor the duty cycle of said PWM drive signal to
determine when it is within the predetermined range of the maximum
drive signal and govern the mode control circuit to control the
voltage control circuit between operating modes.
4. The motor drive controller of claim 1 wherein the voltage
control circuit includes means for passing current bidirectionally
between the energy source and the power control stage.
5. The motor drive controller of claim 1 wherein the voltage
control circuit comprises; a first energy storage element
connectable in series with the energy source; a switch element
coupled between the first energy storage element and the energy
source and operative in open and closed states, when operated in
said closed state, said switch element coupling said first storage
element across the energy source; a second energy storage element
connectable in parallel with the energy source; and a circuit
element coupled between said first and second energy storage
elements and operative to pass energy from said first energy
storage element to said second energy storage element to generate a
voltage potential across said second storage element which controls
the voltage of the drive signal.
6. The motor drive controller of claim 5 wherein the first energy
storage element comprises an inductor element; wherein the second
energy storage element comprises a capacitor element; and wherein
the mode controller is operative between operating modes to pulse
the switch element between open and closed states at a variable
duty cycle.
7. The motor drive controller of claim 5 wherein the circuit
element comprises a diode element connected anode to cathode from
the first energy storage circuit element to the second energy
storage circuit element; wherein the switch element is operated by
the mode controller to remain in the open state in the one
operating mode and to be pulsed between the open and closed states
between operating modes; and wherein the voltage potential across
the second energy storage element in the one operating mode is less
than the energy source voltage and in the other operating mode is
greater than the energy source voltage.
8. The motor drive controller of claim 7 wherein the switch element
is operated by the mode controller to be duty cycle pulsed between
the open and closed states between operating modes; and wherein the
duty cycle sets the voltage potential across the second energy
storage element.
9. The motor drive controller of claim 5 wherein the circuit
element comprises a second switch element operative in open and
closed states; said second switch element operative in the closed
state to pass energy of the first energy storage element to the
second energy storage element; wherein the switch element and
second switch element are operated by the mode controller to be
pulsed complementarily between the open and closed states between
operating modes; and wherein the voltage potential across the
second energy storage element in the one operating mode is less
than the energy source voltage and in the other operating mode is
greater than the energy source voltage.
10. The motor drive controller of claim 9 wherein the switch
element and second switch element are operated by the mode
controller to be duty cycle pulsed complementarily between the open
and closed states between operating modes; and wherein the duty
cycle sets the voltage potential across the second energy storage
element.
11. The motor drive controller of claim 10 wherein the switch
element and second switch element are operated by the mode
controller in the other operating modes to be duty cycle pulsed
complementarily at a fixed duty cycle.
12. The motor drive controller of claim 10 wherein the switch
element and second switch element are operated by the mode
controller between operating modes to be duty cycle pulsed
complementarily at a variable duty cycle.
13. The motor drive controller of claim 1 wherein the voltage
control circuit includes a multiphase converter circuit comprising;
a plurality of first energy storage elements, each said first
energy storage element connectable in series with the energy
source; a corresponding plurality of first switch elements, each
first switch element coupled between a corresponding first energy
storage element and the energy source, each first switch element
operative in open and closed states in phase relationship to said
other first switch elements of said plurality, when operated in
said closed state, each first switch element coupling its
corresponding first storage element across the energy source; a
common energy storage element connectable in parallel with the
energy source; and a corresponding plurality of second switch
elements, each second switch element coupled between its
corresponding first energy storage element and said common energy
storage element, each second switch element operative in open and
closed states in phase relationship to said other second switch
elements of said plurality to pass energy from its corresponding
first energy storage element to said common energy storage element
to generate a voltage potential across said common storage element
which controls the voltage of the drive signal.
14. The motor drive controller of claim 1 wherein the motor is
controlled by a speed control loop that controls the power control
stage to generate a drive signal to maintain the vehicle at a
desired speed; and wherein the mode controller includes means for
controlling the operating mode of the voltage control circuit based
on whether or not the drive signal is sufficient to operate the
vehicle at the desired speed.
15. The motor drive controller of claim 14 wherein the power
control stage is capable of generating a maximum drive signal at
the first voltage potential to control the motor to operate the
vehicle at the desired speed; and wherein the mode controller
includes a sensing circuit for monitoring the drive signal; and a
mode control circuit governed by said sensing circuit to control
the voltage control circuit between operating modes when the drive
signal is determined to be insufficient to operate the vehicle at
the desired speed.
16. The motor drive controller of claim 15 wherein the power
control stage includes means for generating the drive signal as a
pulse width modulated (PWM) signal at the voltage controlled by the
voltage control circuit, the duty cycle of said PWM drive signal
being a measure thereof; and wherein the sensing circuit is
operative to monitor the duty cycle of said PWM drive signal to
determine when it is insufficient to operate the vehicle at the
desired speed and govern the mode control circuit to control the
voltage control circuit between operating modes.
17. The motor drive controller of claim 14 including an inhibit
circuit for inhibiting the mode control circuit from controlling
the voltage control circuit between operating modes when current of
the drive signal is determined to be greater than a predetermined
level.
18. A motor drive control system for an electric vehicle driven by
an electric motor powered by an energy source, said system
comprising: a power control stage coupleable to said motor for
generating a drive signal at a voltage to control said motor at a
desired speed; a first motor drive controller connectable between
the energy source and said power control stage for controlling the
voltage of said drive signal at a first voltage potential, said
first motor drive controller operative to monitor the properties of
said drive signal; and a second motor drive controller connectable
between the energy source and said power control stage for
controlling the voltage of said drive signal at a second voltage
potential in one operating mode and at a voltage potential greater
than the second voltage potential in another operating mode, said
second motor drive controller including a mode controller for
communicating with said first motor drive controller to determine
the properties of said drive signal and for controlling the
operating modes of said second motor drive controller based on said
communicated properties of said drive signal.
19. The motor drive control system of claim 18 including means
governed by said mode controller for connecting said second motor
drive controller between the energy source and the power control
stage based on the communicated properties of said drive
signal.
20. A motor drive control system for an electric vehicle driven by
an electric motor powered by an energy source, said system
comprising: a power control stage coupleable to said motor for
generating a drive signal at a voltage to control said motor at a
desired speed; a first motor drive controller connectable between
the energy source and said power control stage for controlling the
voltage of said drive signal at a first voltage potential; a second
motor drive controller connected, when activated, between the
energy source and said power control stage for controlling the
voltage of said drive signal at a second voltage potential in one
operating mode and at a voltage potential greater than the second
voltage potential in another operating mode, said second motor
drive controller including a mode controller for controlling the
operating modes of said second motor drive controller; and said
first motor drive controller including means for monitoring the
activation status of said second motor drive controller; and means
governed by said monitoring means for connecting the first motor
drive controller between the energy source and said power control
stage based on the monitored activation status of the second motor
drive controller.
Description
RELATED APPLICATIONS
[0001] This Application claims the benefit of the filing date Feb.
6, 2002 of the U.S. provisional application No. 60/354,765, and is
a continuation-in-part-application of U.S. patent application Ser.
No. 10/068,391, entitled "System and Method for Driving An Electric
Vehicle", filed on Feb. 6, 2002, which claims the benefit of the
filing date Feb. 6, 2001 of the U.S. provisional application No.
60/266,736, and is assigned to the same assignee as the instant
application.
BACKGROUND OF THE INVENTION
[0002] The present invention is directed to electric motor drive
controllers in general, and more particularly, to an electric motor
drive controller comprising a voltage control circuit operative in
different operating modes for generating different voltages for a
drive signal to control a motor of an electric vehicle powered by
an energy source.
[0003] A typical electric vehicle draws the energy from an energy
storage device such as a battery, sometimes supported by secondary
energy sources. The power is processed in a drive power control
which controls the voltages and currents which are fed into one to
several electric motors. In general, for slow or small scale
electric vehicles, such as wheelchairs, bicycles or transportation
systems permanent magnet motors are used, i.e. DC, AC or multiphase
machines with permanent excitation.
[0004] Extending the operating range of motors with permanent
excitation generally requires enhancing the voltage and/or current
capabilities of a drive power controller. The limited dynamic range
of the power controller restricts the system to a certain operating
range. As the relationship between current and torque, as well as
between voltage and speed is fixed, the controller has to deliver
very high currents for high torque output, and very high voltages
to achieve high speeds.
[0005] A common solution is using motors with a separately
adjustable field excitation instead of the permanent excitation.
This solution allows additional influence by determining the
relationship between voltage and speed (the Ke-Factor), and current
and torque. With strong excitation high torque at low currents can
be achieved, with weak excitation the motor runs fast at a
relatively low voltage in the other winding. Suitable motors
consist of an additional armature winding which requires the use of
additional slip rings. The drive power controller has to offer
additional circuitry to support the additional winding. Another
approach is adding a gearbox, or a variable transmission between
motor and wheel. For cost reasons these approaches are only
applicable to large scale vehicles, or in special
circumstances.
[0006] An approach related to motors with permanent excitation is a
permanent increase of the power supply voltage, for example by
increasing the number of battery cells. At given dimensions, this
requires reducing the size of the individual cells, increasing the
power supply's impedance. At the same time, the motors can take
more stall current because of the higher voltage. The system's
efficiency would decrease significantly, and special precautions
against overload may be required. Further, the effective resolution
in terms of Volts/bit rises proportionally, i.e. the voltage steps
will become larger. As one consequence, the motors start to run
roughly.
[0007] The present invention provides a solution which overcomes
the drawbacks of the aforementioned solutions to increase the
maximum vehicle speed, while fully maintaining the other key
parameters.
SUMMARY OF THE INVENTION
[0008] In accordance with one aspect of the present invention, an
electric motor drive controller for an electric vehicle driven by a
motor with permanent excitation and powered by an energy source
comprises: a power control stage coupleable to the motor for
generating a drive signal at a voltage to control the motor at a
desired speed; a voltage control circuit connectable between the
energy source and the power control stage for controlling the
voltage of the drive signal at a first voltage potential in one
operating mode and at a voltage potential greater than the first
voltage potential in another operating mode; and a mode controller
for controlling the operating modes of the voltage control circuit
based on properties of the drive signal.
[0009] In accordance with another aspect of the present invention,
a motor drive control system for an electric vehicle driven by an
electric motor powered by an energy source comprises: a power
control stage coupleable to the motor for generating a drive signal
at a voltage to control the motor at a desired speed; a first motor
drive controller connectable between the energy source and the
power control stage for controlling the voltage of the drive signal
at a first voltage potential, the first motor drive controller
operative to monitor the properties of the drive signal; and a
second motor drive controller connectable between the energy source
and the power control stage for controlling the voltage of the
drive signal at a second voltage potential in one operating mode
and at a voltage potential greater than the second voltage
potential in another operating mode, the second motor drive
controller including a mode controller for communicating with the
first motor drive controller to determine the properties of the
drive signal and for controlling the operating modes of the second
motor drive controller based on the communicated properties of the
drive signal.
[0010] In accordance with yet another aspect of the present
invention, a motor drive control system for an electric vehicle
driven by an electric motor powered by an energy source comprises:
a power control stage coupleable to the motor for generating a
drive signal at a voltage to control the motor at a desired speed;
a first motor drive controller connectable between the energy
source and the power control stage for controlling the voltage of
the drive signal at a first voltage potential; a second motor drive
controller connected, when activated, between the energy source and
the power control stage for controlling the voltage of the drive
signal at a second voltage potential in one operating mode and at a
voltage potential greater than the second voltage potential in
another operating mode, the second motor drive controller including
a mode controller for controlling the operating modes of the second
motor drive controller; and the first motor drive controller
including means for monitoring the activation status of the second
motor drive controller; and means governed by the monitoring means
for connecting the first motor drive controller between the energy
source and the power control stage based on the monitored
activation status of the second motor drive controller.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a block diagram schematic of a motor control
system for an electric motor driven vehicle suitable for embodying
the broad principles of the present invention.
[0012] FIG. 2 is a circuit schematic of a booster circuit
embodiment suitable for use in the embodiment of FIG. 1.
[0013] FIGS. 3A-3D are time waveforms exemplifying the operation of
the booster circuit embodiment of FIG. 2.
[0014] FIG. 4 is a circuit schematic of an alternate booster
circuit embodiment suitable for use in the embodiment of FIG.
1.
[0015] FIG. 5 is a block diagram schematic of a booster circuit
employing a bootstrap supply for the switch drive circuits suitable
for use in the embodiment of FIG. 1.
[0016] FIG. 6 is a circuit schematic of a booster circuit including
a multiphase converter suitable for use in the embodiment of FIG.
1.
[0017] FIGS. 7A-7D are time current waveforms exemplifying the
operation of the multiphase converter of FIG. 6,
[0018] FIG. 8 is a circuit schematic of a mode control circuit
suitable for simulation of the embodiment of FIG. 1.
[0019] FIGS. 9, 10 and 11 are simulated time waveforms exemplifying
the operation of the simulation embodiment of FIG. 8.
[0020] FIG. 12 is a circuit schematic of multiphase triangular
waveform generator suitable for simulation of the embodiment of
FIG. 1.
[0021] FIG. 13 are simulated time waveforms of the multiphase
triangular waveforms produced by the simulation circuit of FIG.
12.
[0022] FIGS. 14A, 14B and 14C taken together depict a circuit
schematic of a motor controller suitable for embodying the
principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] As shown in FIG. 1, a motor drive controller 10 including a
boost circuit 11 is located between a fixed-voltage energy source
12, like a battery power supply, for example, and a conventional
drive power control unit 14 that controls at least one motor 16,18
of a vehicle. In one mode of operation, the boost circuit 11
increases the maximum speed of the vehicle motors 16,18 beyond the
limits given by the previously fixed supply voltage 12, by
increasing the voltage by a certain amount, which is then supplied
to the drive power controller 14 over line 20. The booster circuit
11 may be operated in a variety of modes, including constant
voltage increase, variable voltage increase (manual or automatic),
or a transparent voltage bypass mode as will be described in
greater detail herein below. It also supports negative currents,
i.e. recharging the battery power supply 12 using regenerative
energy developed by the motors 16,18 is possible. An optional
connection over lines 22 to the boost circuit 11 allows the power
control unit 14 to automatically adjust the boosted voltage within
predetermined limits, according to given load cases.
[0024] As noted above, the boost circuit 11 may be operative in a
low impedance state (transparent bypass mode), bypassing the power
supply voltage in cases where the increased voltage is not needed
and where lowest supply resistance is essential, and may be
switched to another mode to increase the supply voltage, in steps
or linearly, once the maximum motor speed at the power supply
voltage is approached. Further, the booster 11 may consist of a
multiphase converter to allow phase overlap in order to reduce
overall current ripple which otherwise may stress other system
components such as capacitors. This multiphase converter will be
more fully explained by the description found below.
[0025] The foregoing described approach allows extending the
operating range of motors with permanent excitation 16,18,
characterized by increasing their possible speed while maintaining
their torque. Motors 16,18 and their power supply 12 remain
unchanged, and in most cases the changes to the power drive control
unit 14 are negligible. The method is not restricted to rotational
machines.
[0026] The boost circuit 11 increases the maximum speed of the
vehicle motors 16,18 beyond the limits given by the previously
fixed supply voltage 12, by increasing the voltage by a certain
amount, which is then supplied to power stage(s) 28,30 of the drive
power controller 14 over lines 20. Preferably, the drive power
controller's internal supplies shown at 24 continues deriving its
energy directly from the vehicle's battery power supply 12 over
line 26, i.e. by bypassing the booster circuit 11 of controller 10,
this way adaptations to the maximum operating voltage as well as to
its enlarged range can be avoided in this section 14. The booster
11 may increase the voltage which is solely applied to the drive
control power stage 28,30 of motors 16,18 via line 20.
[0027] In the constant voltage increase mode, the booster circuit
11 increases the maximum speed of the vehicle, as if a power supply
with a higher voltage output were mounted, similar to increasing
the number of battery cells. If a constant voltage increase ratio
is chosen, a straightforward circuit which merely generates a fixed
duty cycle pulse width modulation (PWM) can be used. As the booster
11 may be active all the time, it contributes to a noticeable
efficiency degradation. In addition, because it has to withstand an
increased current flow in the worst case, the booster circuit's
power capabilities will be adequately high.
[0028] An automatic, variable voltage increase mode of the boost
circuit 11 may account for this problem, which can be realized
either as a linear process or in fixed steps. This can be achieved
by adding a simple unidirectional or bidirectional communication
path 22 between drive control 14 and a control circuit 32 of the
booster circuit 11. Here, the drive control 14 can easily determine
the presence or activation of the booster 11. As an example, the
control 14 can output a test signal to a control circuit 32 in
controller 10 over communication path 22 prior to any activation or
during system startup. The controller 14 then detects whether it
receives an elevated voltage, which indicates an attached booster
11. If not found, the drive controller 14 will continue operating
as usual. If a booster 11 is found to be operative, the power
controller 14 commences operation, but now using the voltage
generated by the booster 11 over lines 20 as the main supply for
its power stage 28,30. During operation, the controller 14
continuously checks for potential limits and outputs the need for
the required voltage increase to the control circuit 32 of the
booster 11.
[0029] As an alternative solution, the control circuit 32 within
motor controller 10 may detect the need for and the level of the
voltage increase on its own, by observing the PWM duty cycles of
the drive signal 34,36 delivered by the drive control power stage
28,30 over communication path 22, and, if desired, also the motor
currents of the drive signal 34,36. This way the drive power
control 14 need not support any additional communication. The only
structural changes needed are that the dual supplies are made
available externally, i.e. bypassed battery voltage over lines 26
and 38 for internal supplies 24 and 40 and boosted voltage over
line 20 for the power stage 28,30, and that the control units 32
and 42 account for the higher possible speed.
[0030] Access to the separate supplies is given in most cases, as
the power input (line 26) and the power stage 28,30 of the drive
controller 14 are separated by means of an isolation relay 44,
protecting against malfunction and reverse polarity, following
federal regulations. For continued safety, another similar
isolation relay 46 can be used in the motor controller circuit 10.
Then, the drive control 14 may disable its own isolation relay 44
by control unit 42 when it detects an attached or operative booster
circuit 11, to avoid simply short circuiting the output voltages of
the booster 11 and controller 14.
[0031] In practice, performance may be also achieved if the drive
control unit 14 also controls the output voltage of the motor
controller 10 in the various modes. Generally, the control (32) of
the booster circuit 11 within controller 10 may work as follows: at
high drive signal currents, the voltage increase of the booster
circuit 11 should be low (transparent voltage bypass mode), to
avoid extreme stress by a further increased current flow in stall
conditions which otherwise would be subjected to the system due to
the higher operating voltage. At sufficiently low drive signal
currents, the voltage generated by controller 10 can increase to
the desired level. The drive power control 14 does so when
detecting that the voltage of its drive signal 34,36 to the motors
16,18 approaches the maximum value at the present power stage
voltage, e.g. approaches within a predetermined range of 100% duty
cycle. It then commands the booster 11 via control circuit 32 over
lines 22 to supply more voltage (constant or variable voltage
increase mode), if possible, i.e. if current and other limits are
not exceeded.
[0032] Alternatively, controller 14 may supply a signal
representative of the drive signal over lines 22 to control circuit
32 when the drive current and other limits are not exceeded so that
control 32 may monitor the drive signal and determine itself when a
voltage increase is needed, i.e. a mode change.
[0033] A block diagram of a typical boost, or step-up circuit 11
suitable for use in the motor controller embodiment 10 is shown in
FIG. 2. Basically, a first energy storage element which may
comprise an inductance L is connectable in series with the positive
terminal of the battery source (INPUT+). For this embodiment, a
single switch S1 is coupled between the first energy storage
element L and the negative terminal (INPUT-) of the battery source
and in one mode of operation, is cycled between open and closed
states at a frequency between some kHz and several MHz, depending
on size and architecture of the storage element L. The cycling of
switch S1 may be performed at a pulse width modulation (PWM) ratio,
i.e. the duty cycle of the switch, which determines the
relationship between input and output voltage of the storage
element L. A second energy storage element which may comprise a
capacitor C is connectable in parallel with the terminals INPUT+
and INPUT- of the battery source. A diode D is connected anode to
cathode from storage element L to the storage element C. The
voltage developed across the capacitor C controls the voltage of
the drive signal via line 20 as shown in the block diagram
schematic of FIG. 1.
[0034] Referring to FIG. 2, as S1 closes or conducts, energy and
current builds up in the inductor L. After a specified duty cycle
time, S1 opens or isolates and the built up energy in inductance L
is transferred to the capacitor C or the output via the diode D.
Since the energy is transferred discontinuously, capacitor C
smoothes the voltage appearing at the output, i.e. over line 20.
The waveforms of FIGS. 3A-3D illustrate the switch states of S1 and
corresponding currents in the circuit of FIG. 2.
[0035] The voltage ratio between the voltage across capacitor C or
output voltage and the voltage of the battery source is determined
by the duty cycle of switch S1. For example, a switch S1 duty cycle
ratio of approximately 33% can cause a voltage increase of
approximately 50% over the voltage of the battery source. In
transitioning between modes, switch S1 may be pulsed with a
variable duty cycle from 0% to a predetermined duty cycle, for
example, over a predetermined period of time to cause the output
voltage to increase gradually to the desired level. The desired
voltage across capacitor C or output voltage is maintained above
the voltage of the battery source by the diode D, i.e.
substantially no diode current flows when switch S1 closes (see
FIGS. 3A and 3D), notwithstanding the voltage at node N1 being duty
cycled to zero potential.
[0036] In an alternate booster circuit embodiment as shown in the
circuit schematic of FIG. 4, the diode D is replaced by a second
switch S2, forming a synchronous half bridge construction wherein
switches S1 and S2 are pulsed complementarily between their open
and closed states. That is, when switch S1 is closed, switch S2 is
opened, and vice versa. Because the diode's forward voltage drop
decreases circuit operating efficiency significantly, especially at
low voltages, replacing the diode with a switch S2 of low impedance
reduces the voltage drop substantially, thus increasing efficiency.
At the same time, the synchronous construction allows for a reverse
energy transfer through switch S2 when closed, which is definitely
needed in electric vehicles. Because of the cycling, the energy
transfer from this circuit embodiment to the output is done in
"chunks", which results in a current ripple on the output: the
current flow cycles between zero and a value higher than the load
current. A suitable capacitor C attached to the output (line 20) is
scaled to even out this ripple, converting it to a residual voltage
ripple.
[0037] Multiple phase converters, i.e. multiple circuits containing
elements L, S1 and S2, for example, may spread the conversion task
over several smaller, interleaving channels which will be explained
in greater detail herein below in connection with the circuit
embodiment illustrated in FIG. 6. This way, the current ripple can
be reduced as well as the residual voltage ripple. For example, as
a 50% increase in voltage requires a switch S1 duty cycle of 33.3%,
three interleaving converters can reduce the ripple to the lowest
possible value, the energy transfer is substantially seamless. The
remaining ripple is caused by the inductors, no longer by the load
current.
[0038] In contrast to voltage regulators, where a control loop
stabilizes the output voltage by adjusting the PWM duty cycle
depending on output voltage deviations from a reference level, such
a control is not desired in the suggested booster circuit
embodiments. The duty cycle should remain either fixed, or
preferably, varied or steered under direct control by the drive
power controller 14 via communication path 22 and control circuit
32. Note that in order to support the transparent bypass mode, the
circuit embodiment of FIG. 4 should be able to turn on (close) the
upper switch S2 all the time and keep switch S1 open.
[0039] Typical bridge configurations such as in the embodiment of
FIG. 4 are restricted in these terms: the on-time of the upper
switch S2 is limited. This stems from the fact that the switches S1
and S2 are generally built using semiconductors, such as metal
oxide semiconductor field effect transistors (MOSFETs) or insulated
gate bipolar transistors (IGBTs), for example. In general, the
circuits within control 32 driving these components do not support
a "floating supply", i.e. the voltage of node N1 for switch S2. The
latter designates a supply which is referenced to the potential of
switch S2.
[0040] To achieve the driving of a switch with a "floating supply",
most circuits use a "bootstrap" supply as shown by the circuit
embodiment of FIG. 5. Referring to FIG. 5, switches S1 and S2 are
driven by drive circuits 50 and 52, respectively, which may be part
of control 32 as shown in FIG. 1. Since switch S1 is referenced to
a fixed voltage potential (INPUT-), the drive 50 may be operated
from the voltage potential of the internal supply 40 without
adjustment. However, switch S2 is referenced to the voltage of node
N1 which is floating. Thus, the drive 52 is referenced to the
"bootstrap" voltage generated from a circuit consisting of a diode
D' and a capacitor CB referenced to the voltage of the node N1.
Permanent cycling of the booster stage refreshes the charge in the
bootstrap supply capacitor CB via diode D'. The voltage developed
across CB may then be used as the floating supply for drive 52.
However, adding 100% duty cycle capability of switch S2 to support
the transparent bypass mode requires maintaining the voltage across
CB in some manner notwithstanding that no cycling of drive 52 takes
place. Some suitable circuit arrangements (not shown) for this
purpose include using a charge pump, a transformer or similar
circuit arrangements.
[0041] Finally, as referred to herein above, a multiphase or
polyphase converter may be used in the embodiment of FIG. 1 for
smoothing out the voltage at the output, i.e. across capacitor C. A
suitable circuit arrangement for such a converter using three
voltage booster circuits 11A, 11B, and 11C by way of example is
shown in FIG. 6. Each booster circuit 11A, 11B and 11C includes an
inductor L and set of complementarily operated switches. For
example, booster circuit 11A includes inductor L1 and switches S11
and S12 patterned after the circuit embodiment described in
connection with FIG. 4. Likewise, booster circuits 11B and 11C
include: inductor L2 and switches S21 and S22, and inductor L3 and
switches S31 and S32, respectively, each in the same circuit
arrangement as booster circuit 11A. All of the booster circuits
11A, 11B and 11C feed the sum I(sum) of their respective
interleaved currents I1, I2 and I3 into the common capacitor C.
[0042] As the switching times of the switches of the booster
circuits 11A, 11B and 11C and their corresponding currents I1, I2
and I3 are interleaved as shown by way of example in the time
waveforms of FIGS. 7A-7C, the resulting overall current I(sum) can
be smoothed as shown in time waveform of FIG. 7D. The time
waveforms of FIGS. 7A-7D illustrate a three-phase converter at an
ideal interleave, which is, at an approximate 50% voltage increase,
a duty cycle of 33.3%. Also, the load is spread over three similar
booster stages 11A, 11B and 11C, each of which being smaller in
size. In practice, this is an advantage from both a circuit
designer's and a manufacturer's point of view; the overall design
benefits from higher frequencies, higher efficiency, reduced
parasitic effects and reduced component size.
[0043] As noted above, the preferred embodiment of the invention is
shown in FIG. 1. More specifically, shown in FIG. 1 is an energy
source or battery 12 coupled to the motor controller 10 which
includes the internal supply 40, mode control 32 and the booster
circuit 11, and the drive power control 14 which includes the
internal supply 24, control 42 and power stage 28,30. The power
stage 28,30 generates the drive signal(s) 34,36 to control the
electric motor(s) 16,18. The drive power control 14 draws its
supplemental power directly from the battery via internal supply 24
using the bypass line 26, and its power stage(s) 28, 30 derives the
voltage and energy from the booster circuit 11 via conductor 20.
The whole arrangement may be mounted in a variety of electric
vehicles. The controller 14 can send information about activation
and required voltage increase to the booster 11 from control 42 to
control 32 using communication path 22. This information can be
sent over communication path 22 in the form of any suitable
electrical signal including a Pulse-Width Modulated (PWM) drive
signal, an varying analog signal, a serial/digital bit stream
signal, or any conventional bus form of data signal.
[0044] In one mode of operation, the booster circuit 11 is absent
or inoperative and the internal isolation relay 44 of motor
controller 14 is activated, which connects the power stage(s) 28,30
directly to the battery supply 12 via bypass line 26. Once the
controller 14 detects via communication path 22 that the booster 11
is operative or attached, it disables activation of its internal
isolation relay 44. The relay 46 in the controller 10 replaces its
function and also satisfies or accounts for safety regulations. The
booster's output voltage (voltage across capacitor C) is then fed
via line 20 into the power stage(s) 28, 30.
[0045] If the drive controller 14 recognizes that no booster
support for increase of vehicle speed is needed, it can force the
booster 11 into the previously described transparent bypass mode,
disabling any cycling of switches S1 and S2 and establishing a low
resistance path through the booster via switch S2. Alternatively,
the efforts related to the requirement of a 100% duty cycle support
needed for bypassing can be saved if the drive controller 14
reactivates the internal isolation relay 44 instead once it
disables the booster 11. In these situations all power to the
booster 11 can be cut via relay 46.
[0046] Alternatively, communication path 22 may be used for the
approach where the booster circuit 11 via control 32 derives
information about the drive signal 28,30 of controller 14, allowing
the control circuit 32 of motor controller 10 to determine the
needed amount of voltage booster increase by itself. In this mode
of operation, the isolation relay 44 of controller 14 may be
disabled manually, since the controller 14 may not detect the
absence or presence of a booster 11. For the same reason, the
above-described use of the internal isolation relay 44 as an
alternative to the transparent mode bypassing is not available.
[0047] As noted above, the booster circuit 11 may remain active all
the time, reducing the operational efficiency thereof
unnecessarily. Hence, in the alternative, the booster circuit 11
could stay completely passive during the time where it identifies
that elevated voltages are not needed, or when high currents appear
(i.e. transparent voltage bypass mode)--doing so, the energy
consumption of a permanent cycling, which is typical for switching
converters, can be completely avoided during most of the operating
time.
[0048] Accordingly, the voltage booster circuit 11 may be operated
by mode control 32 to switch in a further energy saving bypass
mode, or low-impedance mode. In this mode, the booster 11 has to
support 100% "on" time for one of its switches S2 which may be
accomplished as explained herein above. Thus, in this
configuration, the switch component's switching losses are
eliminated, and the inductor's (L) magnetic core can be shrunk to a
small size, compared to a permanently cycling solution. As no
cycling takes place when the booster 11 is subjected to very high
currents, no inductance is needed which otherwise would be needed
to keep the booster 11 operative and cycling. In other words, the
core of inductor L is allowed to saturate during these operating
conditions. Then, the only possible source for losses in this mode
is DC resistance (static conduction loss), which primarily consists
of switch S2 resistance, inductor winding and internal booster
wiring. In contrast to a live, cycling booster, the series
impedance of the bypassed circuit is substantially lower. In
addition, all energy consumption due to a permanent cycling of the
internal switches will be saved. In the alternative, if the drive
power controller 14 does not need booster support, it forces the
booster 11 into a stand by mode and activates the internal
isolation relay 44 instead, thus bypassing the current path 20
through the booster 11.
[0049] The present embodiment generally applies to cost effective
electric motors with permanent excitation (i.e. when using
permanent magnets), which have a fixed relationship between voltage
and speed, as well as between current and torque. These motors are
widely used in slow vehicles, such as wheelchairs, electric
bicycles or transportation systems. In these applications, the
required current capability of the power control unit is determined
by the load resistance, i.e. primarily by the motor winding
resistance. Subjected to a stall condition, the motor will take the
maximum current, and deliver the maximum torque, which is common
practice on this type of machines. As the voltages and currents do
not change in the described typical embodiment of the invention,
the respective performance characteristics of the overall
propulsion unit can be maintained. The impedance matching between
power source 12, motor controller 10, power stage(s) 28,30 and
motors 16,18 can be kept at an optimum. The smooth run of the
motors is also maintained, because the resolution of a typical
power stage of conventional controller 14, expressed as Volts/bit,
remains unchanged, in contrast to a solution where the operating
voltage is permanently increased. The only effective change is that
the maximum speed of the motor 16,18, thus vehicle, can be
increased when needed. During this time the current consumption is
relatively low, allowing a higher impedance of the power supply,
which matches the given behavior of the activated booster converter
circuit 11. The booster circuit 11 even increases the amount of
power the system can process, as the higher motor speed is directly
linked to higher power levels at a given system structure.
[0050] Hence, the embodiment of FIG. 1 provides a motor controller
10 having the following attributes:
[0051] regenerative or negative current flow to return energy back
to the battery;
[0052] constant voltage increase mode providing for a fixed duty
cycle PWM; or, in the alternative,
[0053] an automatic variable voltage increase circuit via a
communication path 22 between the booster circuit 11 via control 32
and the controller 14 (if booster is present, booster is used as
the main power supply via line 20 to driver power stage and the
controller 14 continuously checks for limits and outputs the
required voltage increase signal via path 22 to the booster 11); or
in the alternative,
[0054] a booster control mode wherein the booster circuit 11 via
control 32 detects the need for and the level of voltage increase
by observing the PWM duty cycles being deliver to the driver power
stage 28,30; and, as an option,
[0055] passive booster mode during periods of no boost for
conserving energy by reducing or eliminating the booster circuit's
cycling periods.
[0056] A suitable embodiment of the mode control 32 for use in
motor controller 10 is shown, by way of example, in the circuit
schematic of FIG. 8 which may be used for simulation purposes.
Simulated time waveforms of critical nodes of the mode control
circuit embodiment after startup are shown in FIGS. 9, 10 and 11.
Such simulation waveforms closely parallel real physical
measurements and are very useful to visualizing the circuit's
operation. A fixed PWM on the input node IN is representative of a
signal generated by control unit 42, routed over communication link
22, indicating that an increased voltage should be supplied to the
power stages 28,30, i.e. the drive signal 34,36 is within the
predetermined range of maximum. Further, the operating frequencies
(capacitors)of the simulation embodiment are scaled in a way that
the waveforms can be easily observed. In the present embodiment,
the PWM of the drive signal 34,36 runs at a frequency of
approximately 100 kHz, but is scaled as illustrated by the PWM
waveform 60 in FIG. 9.
[0057] Referring now specifically to FIG. 8, the circuitry around
transistors Q3 and Q2 switches in the battery supply V2 which may
be on the order of 24 volts, for example, to an internal supply SW
at approximately the same voltage level, once some voltage on the
input IN is detected which occurs at time O in the waveforms of
FIGS. 9, 10 and 11. The simulation waveform 62 in FIG. 11 shows the
rise of the voltage SW from 0-2 milliseconds (ms). More
specifically, the PWM signal IN drives the base of the NPN
transistor Q2 via resistor divider network R33 and R34 to switch Q2
"on", i.e. conducting. When "on", Q2 drives the base of PNP
transistor Q3 via a divider/filter network comprising resistors
R35, R36, R37 and capacitor C17 to switch Q3 permanently "on" which
conducts the voltage of V2 to the circuit node SW. Note that when
Q3 is switched on, the voltage at the node DRV which is the
connecting node of components C17, R35 and R37 falls from the
battery voltage potential to near zero as shown by the waveform 63
in FIG. 10.
[0058] In the shown simulation, the circuit combination of NPN
transistor Q4 and zener diode D4 coupled between nodes SW and SUP
simulates a voltage regulator. A resistor R45 coupled between node
SW and the zener D4 maintains a voltage across zener D4 which is
used as a reference voltage to regulate the voltage at SUP to
approximately 12 volts (refer to waveform 64 in FIG. 11). The
voltage at node or bus SUP is the internal supply for the mode
controller simulation circuitry. There may be one or more
decoupling capacitors connected between the SUP and battery common
as exemplified by capacitor C18. A resistance divider circuit
connected between the internal supply and battery common and
comprising series resisters R6, R40, R39, R38 and R4 produces
various reference voltages. For example, reference voltages V1, V2,
V3, and V4 are produced at the nodes of the series resistors.
[0059] The input signal IN is filtered through a single pole filter
circuit comprising resistor R2 and capacitor C1 and compared with
the reference voltage V4 is a comparator circuit X18. More
specifically, a noise-filtered IN signal is coupled to the +input
of X18 through resistance R1 and reference voltage V4 is coupled to
the -input of X18. Some positive feedback for comparator circuit
X18 is provided by resistor R3. Accordingly, comparator X18
operates as a Schmitt trigger, to ensure clean switching
transitions at its output (via pull up resistor R30) when IN signal
rises above and falls below reference V4. Thus, the output of X18
is representative of the PWM drive signal in frequency and duty
cycle.
[0060] This signal (output of X18) is coupled to the emitter of an
PNP transistor Q1 via the series combination of resistor R8 and
capacitor C3 which is clamped to the SUP bus by a diode D1. The
base of Q1 is also referenced to the SUP bus. The circuit transfers
the charge stored in C3 to C2/R7 on every cycle. In this manner,
the frequency of the PWM signal output by X18 is converted to a
voltage which appears at node ENA. The voltage of ENA is compared
with reference V1 by comparator circuit X17. If the frequency
and/or duty cycle of the PWM signal is at the right level to
indicate activation of the booster, there will be sufficient
voltage generated at node ENA as shown by the waveform 66 in FIG. 9
to enable X17. However, the outputs of comparator circuits X17 and
X22 are "or"ed together. So, comparator X17 can not be enabled
without comparator X22 being enabled.
[0061] Comparator X22 compares the voltage at node SW with
reference V1 and thus, is enabled only if there is sufficient
voltage on SW (i.e. battery voltage). If the aforementioned two
conditions are met, the common output line PRECH of comparators X17
and X22 goes positive via pull up resistor R46, representing the
signal which initiates the voltage booster stage 11 activation
which occurs at 68 (5-6 ms) as shown in FIG. 11. Activation of the
booster circuit is initiated by precharging the power stage supply,
which has a heavy capacitive load on it. Precharging of the
capacitors of the power stage supply substantially close to the
battery source voltage is performed as a practical matter so that
when the contacts of the relay 46 (see FIG. 1)are closed a surge of
current therethrough will not occur. High currents due to an
instantaneous voltage difference across the relay contacts can be
destructive to the relay contacts.
[0062] Components R55 and C21 simulate the capacitor precharge
process. The voltage across capacitor C21 represented by node ISO
increases exponentially with charge input as shown by waveform 70
in FIG. 11 (5 . . . 11 ms). A voltage representative of ISO
produced by the resistor divider network R54 and R53 is coupled to
the +input of a comparator X24 and a voltage representative of the
battery voltage SW produced by the resistor divider network R50+R51
and R52 is coupled to the -input thereof. Thus, if the voltage ISO
reaches a sufficient level near the battery voltage SW, comparator
X24 is enabled and allows the control voltage at node CTRL to
increase as shown by the waveform 72 in FIG. 11 (9 ms). Note that
the +input of X24 is clamped to the common output of comparators
X17 and X22 via diode D5 as a precaution.
[0063] More specifically, when X24 is enabled, an average voltage
of the PWM signal output of X18 is produced at the node CTRL using
a simple two pole RC filter comprising the circuit elements R9,
R10, R11, R12, C4, C5, C15, C16. The average voltage is scaled to a
certain range by the resistor divider network of R9, R10, and R11.
In the embodiment, R10 is connected between the output of X18 and
node N2; R9 and C16 are connected in parallel between the SUP bus
and node N2; R11 and C4 are connected in parallel between node N2
and battery common; R12 is connected between node N2 and the node
CTRL; C15 is connected between node CTRL and the SUP bus; and C5 is
connected between node CTRL and battery common.
[0064] Node CTRL is coupled to the +input of a comparator X19 and
the -input of a comparator X20. The comparators X19 and X20 make up
a window comparator circuit referenced to the reference voltages V2
and V3. The window comparator X19,X20 has a common output which is
pulled up to the SUP bus by Resistor R41 when enabled. As the
voltage of the CTRL node increases through reference levels V3 and
V2, a disable DIS pulse is generated by the window comparator X19,
X20 as shown by the waveform 74 in FIG. 10 (10 . . . 11 ms). The
DIS signal is coupled to the switch drivers (not shown) in order to
reset the switch drivers before activation which is a peculiarity
of the drivers used in the present embodiment.
[0065] The CTRL node is also connected to the +input of another
comparator X23 which is referenced to the reference voltage V2.
When the voltage of the CTRL node exceeds V2, the output of X23 is
enabled or pulled up to the SUP bus through resistor R56 as shown
by the waveform 76 in FIG. 11 (11 ms). The output of X23 drives the
isolation relay 46 causing closure of its relay contacts which
connects the battery source 12 to the booster circuit 11 (FIG. 1).
Note that, at this time, the voltage across the isolation relay
contacts is sufficiently low. Refer to waveforms 62 and 70 at
approximately 11 ms in FIG. 11. Thus, closure of the relay contacts
fully energizes the booster power stage 11.
[0066] The circuits comprising comparators X8 and X15 produce the
PWM signal coupled to the switch drivers for pulsing the switches
S1 and S2 in accordance with a duty cycle. In the present
embodiment, the circuitry of X15 generates a triangular waveform at
node OSC. More specifically, a reference voltage V5 is produced by
a resistance divider network R15 and R16 connected between the SUP
bus and battery common. Voltage V5 is coupled to the +input of X15.
The output of X15 is coupled through resistor R13 back to the
-input thereof which is coupled to battery common through a
capacitor C6. In addition, positive feedback is provided by the
resistor R14 to cause the reference voltage V5 to switch between
upper and lower levels as the output of X15 is enabled and disabled
through pull up resistor R32.
[0067] So, as the SUP bus increases in voltage (FIG. 11, waveform
64), the voltage at node OSC increases commensurately therewith as
shown by the waveform 78 in FIG. 9. When the waveform 78 exceeds
the upper level of V5, X15 is disabled causing the waveform to
decrease in voltage and V5 to switch to the lower level. When the
waveform falls below the lower level of V5, X15 is enabled again
causing the waveform to increase in voltage and V5 to switch to the
upper level. This cycle is repeated to generate the uniform
triangular waveform shown at 78 in FIG. 9 at a frequency set
R13-R16 and C6.
[0068] The CTRL node is also coupled to the +input of another
comparator circuit X21 which is used to generate a voltage at node
CTRL2 which in turn is compared with the triangular waveform OSC in
comparator X8 to generate the PWM signal. The circuitry around X21
looks like a rectifier circuit because of the diode D3, but its
purpose is to prevent excessive differential voltage between the
inputs of the PWM comparator X8. More specifically, the output node
X of X21 is coupled through a pull up resistor R44 to the SUP bus
and through the diode D3 to the node CTRL2 which is also coupled to
the SUP bus through resistor R42. Node CTRL2 is coupled back to the
-input of X21 and to ground through a parallel combination of R43
and C19. Actually, R42 and R43 produce a reference voltage at node
CTRL2 which is below, but relatively close to, the voltages of the
triangular waveform 78 as shown by waveform 80 in FIG. 9. When the
voltage at node CTRL exceeds the voltage at node CTRL2 which occurs
around 13 ms, the output X of X21 is enabled as shown by the
waveform 82 in FIG. 9. X21 forces the voltage at node CTRL2 to
follow substantially the voltage at node CTRL whenever it is
greater than the reference voltage defined by R42 and R43..
[0069] As the voltage at CTRL2 intersects the triangular waveform,
X8 begins to generate the PWM output via pull up resistor R17 as
shown by pulse train waveform 84 starting at about 16 ms in FIG.
10. Diode D2 links the rectangular output of X8 with the pulsed
output of X15 in such a way that a predetermined PWM duty cycle,
like 50%, for example, is never exceeded. This phenomenon is shown
in the waveform 84 by the small pedestal preceding each pulse which
is clamped to the voltage across diode D2 when the output of X15 is
pulled "low". The thin negative spikes on the PWM signal shown in
FIG. 10 which are always present after activation (>3 ms) are
more a product of the simulation than really present in the
circuit, they indicate the effect of D2's parasitic capacitance.
Table 1 below provides exemplary values of the circuit components
used in the present simulation embodiment as well as model numbers
for the integrated circuits.
1TABLE 1 COMPONENT VALUES FOR SIMULATION CIRCUIT (FIG. 8) R1 10K
R30 4.7K R2 2.2K R32 4.7K R3 220K R33 10K R4 1K R34 10K R6 6.8K R35
470 .sup. C1 .001 .mu.F R7 330K R36 10K C2 .010 .mu.F R8 3.9K R37
10K C3 .001 .mu.F R9 56K R38 1K C4 .047 .mu.F R10 100K R39 1K C5
.047 .mu.F R11 47K R40 3.9K C6 .012 .mu.F R12 20K R41 4.7K C15 .047
.mu.F R13 100K R42 100K C16 .047 .mu.F R14 100K R43 47K C17 .010
.mu.F R15 48K R44 33K C18 .010 .mu.F R16 48K R45 10K C19 .010 .mu.F
R17 4.7K R46 10K C21 010 .mu.F R50 18K Q1 BC557C R51 4.7K Q2 BC546
R53 4.7K X8 LM311 Q3 BC328 R53 22K X15 LM311 Q4 BC338 R54 100K X16
LM339A R55 100 .sup. X17, X22, X24 LM339A D1 IN4148 R56 10K X21
LM311 D2 IN4148 X19, X20, X23 LM339A D3 IN4148 D4 IN759 (Z) D5
P44148
[0070] In the present embodiment, once the input PWM signal IN
becomes invalid, a low voltage limit is violated, or an unexpected
voltage drop across the relay contacts appears, CTRL will be
blocked or pulled low, thus disabling the signal PWM via X21 and
relay 46 via X23 immediately. With relay 46 disabled, the booster
circuit 11 is deactivated, i.e. without power. Also, in the present
simulation embodiment, the duty cycle of input PWM signal at node
IN received from controller 14 is a measure of the motor drive
signal generated by the power stage(s) thereof or a voltage
increase requested by the controller 14. When the duty cycle at
node IN exceeds a predetermined level as set by X21, the booster
circuit operates in a mode in which the duty cycle of the PWM
switch control (PWM) is permitted to vary along with the measured
duty cycle value of signal IN (CTRL). If the signal IN remains
below the predetermined level, the booster circuit may operate in
the transparent bypass mode as described herein above.
[0071] However, it is understood that the voltage booster circuit
11 is also operative in the constant voltage increase mode in which
the duty cycle of switch control PWM is fixed to a predetermined
value, like 33.3%, for example, to produce a constant voltage
increase at the booster circuit of approximately 50%. This fixed
duty cycle in switch control could be rendered operative when the
drive signal is within a range of its maximum value. For example,
when the duty cycle at node IN becomes within, say 80% of a 100%
duty cycle, for example, the fixed PWM switch control could be
activated. This mode of operation could be accomplished by a
modification to the circuitry of X21. That is, instead of allowing
the voltage intersecting the triangular waveform at X8 to vary when
CTRL exceeds a predetermined level, it can be generated as a fixed
voltage intersecting the triangular waveform at a level to produce
a fixed duty cycle at the node PWM for switch control. In fact, the
mode control 32 may include both such circuits and chose which one
to use based on a determined mode of operation.
[0072] As noted above in connection with the embodiment of FIG. 6,
the charge ripple on capacitor C of the booster circuit 11 can be
smoothed by multiphase interleaving of charge input from a
plurality of complementarily switched circuits. This may be
accomplished in the present embodiment, by producing triangular
waveforms separated in phase. Thus, a common reference voltage will
intersect the waveforms at different phases to produce switch
control PWM pulse trains in the same phase relationship with each
other. The phased apart pulse trains control correspondingly the
plurality of switched circuits to produce interleaved pulsed charge
waveforms as exemplified by FIGS. 7A-7C. A suitable embodiment of a
circuit to generate three phased apart triangular waveforms for use
in producing the interleaving switch control PWM signals is shown
by way of example in FIG. 12.
[0073] The circuit embodiment of FIG. 12 includes three
interconnected circuits surrounding comparators X4, X5, and X6,
respectively, which are all substantially the same as that
described for the triangular waveform generator X15 in the
embodiment of FIG. 8. The three phased apart voltage waveforms, Va,
Vb, and Vc, which are illustrated in the time graph of FIG. 13, are
generated at the nodes a, b and c, respectively. In the present
embodiment, the outputs of the comparators X4, X5 and X6 are
coupled to battery common through capacitors C4', C5' and C6',
respectively. Also, interconnection of the three circuits is
accomplished in the present embodiment by coupling the output of X4
to node b of the X5 circuit through resistor R13'; coupling the
output of X5 to node c of the X6 circuit through resistor R14'; and
coupling the output of X6 to node a of the X4 circuit through
resistor R15'. Each of the nodes a, b and c are clamped to the SUP
bus by diodes D1', D3' and D2', respectively. For simulation
purposes, D1, R16 and C7 form a network which delays the rise time
of X4 on startup. D2 and D3 account for the additional capacitance
of D1, keeping symmetry. Typical values for the circuit components
of the embodiment of FIG. 12 are provide in Table 2 below.
2TABLE 2 COMPONENT VALUES FOR 3-PHASE TRIANGULAR WAVE GEN. (FIG.
12) R1' 48K C1' 120 .sub.pF R2' 48K C2' 120 .sub.pF R3' 100K C3'
120 .sub.pF R4' 100K C4' 10 .sub.pF R5' 48K C5' 10 .sub.pF R6' 48K
C6' 10 .sub.pF R7' 100K C7' 100 .sub.pF R8' 100K R9' 48K D1', D2',
D3' IN4148 R10' 48K X4, X5, X6 LM311 R11' 100K R12' 100K R13' 1 M
R14' 1 M R15' 1 M R16' 1 M R17' 10K R18' 10K R19' 10K
[0074] FIGS. 14A, 14B and 14C together illustrate a circuit
schematic of an actual embodiment of the motor controller 10 having
a control portion 32 which is substantially the same as described
in connection with the simulation embodiment of FIG. 8 except that
the actual embodiment includes the generation of three phased apart
switch control PWM pulse trains, PWM1, PWM2, and PWM3 as described
in connection with the simulation embodiment of FIG. 12. The small
rectangular blocks in FIGS. 14A-14C represent resistive elements.
Referring to FIG. 14A, a signal representative of the PWM drive
signal or the desired voltage increase may be conducted to motor
controller 10 over path 22. The circuits of T16 and T14 are the
same as described for circuits Q2 and Q3 for detecting the presence
of the drive control signal and connecting the battery voltage to
the control circuit. The circuit IC9 is a commercial integrated
circuit voltage regulator which replaces the circuit of Q4/D4 of
the simulation. Capacitors are coupled between the voltage supplies
and battery common on both sides of IC9 for reducing ripple on the
supply buses.
[0075] Circuitry of T13 is the same as that described for Q1 and
the circuits of IC7D and IC7C are comparable to the circuits of X22
and X17 which produce the precharge signal. The circuitry of IC8A
which is similar to the circuitry of X24 establishes that the
voltage across the contacts of relay 46 is within the permitted
range to close the contacts of the relay. The comparator IC4A
activates the relay and comparators IC7A and IC7B form the window
comparator for generating the gate driver reset pulse DISABL. The
circuitry of IC8B is the same as that for X18 and the following two
pole filter circuit is the same as described for the simulation.
Also, the circuit of IC4B is the same as the circuit for X21 which
produces a reference signal DCI for intersecting the three phase
triangular waveforms to produce the three phased apart switch
control PWM pulse trains.
[0076] Referring to FIG. 14B, the circuits of IC6A, IC5A and IC3A
are the same as described for the simulation circuit of FIG. 12 for
producing the three phased apart triangular waveforms as
exemplified in FIG. 13. The waveforms generated by IC6A, IC5A and
IC3A are compared with signal DCI in circuits IC6B, IC5B and IC3B
to produce the phased apart switch control signals PWM1, PWM2 and
PWM3, respectively, much the same way as described for X8 in the
simulation embodiment. The switch control signals PWM1, PWM2 and
PWM3 are coupled to the inputs of corresponding gate drivers in
integrated circuits IC1 and IC2 which may be of the type bearing
model number HIP4081 which in turn are coupled to three
corresponding sets of MOSFET type switches S11 and S12, S21 and
S22, and S31 and S32 as shown in FIG. 14C. It is understood that
more powerful gate drivers may be added between the HIP4081 drivers
and the MOSFET switches to supplemental the driving power of the
HIP4081 drivers. Alternatively, one three-channel HIP4086 IC gate
driver can be used instead of the two HIP4081 integrated circuits
as shown in FIG. 14B. Also, additional and more powerful gate
drivers may be used when driving large MOSFETs.
[0077] In the present embodiment, the gate drivers are adjusted
properly by the circuitry shown in FIG. 14C for the floating
voltages of nodes N11, N12 and N13 much the same way as that
described for the embodiment of FIG. 5 herein above. Also, as shown
in FIG. 14C, the embodiment includes two MOSFET switches connected
in parallel and driven together for each switch S11, S12, S21, S22,
S31 and S32 to handle the particular current capacity of the
exemplary embodiment.
[0078] Still referring to FIG. 14C, the precharge signal is coupled
to an integrated switch IC10 which includes a form of current
limitation for charging the capacitor bank shown at 90 which is
connected to the other side of the contact of relay 46. The signal
ISO is provided to the control circuit of FIG. 14A as a measure of
the voltage across the capacitor bank. The RELAY signal drives
relay 46 through the circuitry of T15. When the contact(s) of relay
46 are closed, the battery source is connected to the booster
circuit 11 which is similar to the embodiment described in
connection with FIG. 6.
[0079] External power inductors which may be on the order of 8
microhenries, for example, are connected to the circuitry at
terminals TA, TB and TC between the battery source and nodes N11,
N12 and N13, respectively. MOSFET switches S11, S21 and S31 are
coupled respectively between nodes N11, N12 and N13 and battery
common and MOSFET switches S12, S22 and S32 are coupled
respectively between nodes N11, N12 and N13 and common capacitance
C comprising parallel connected capacitor banks 92, 94, 96 and 98.
The voltage generated across the common capacitance is supplied to
the power stages 28,30 to generate the drive signal(s) 34, 36 as
shown in FIG. 1.
[0080] While the foregoing described embodiments utilize discrete
circuit elements, it is understood that alternatively, the control
circuitry may be embodied in a programmed microprocessor-based
controller having a CPU, memory, and inputs and outputs including
PWM outputs. Using microprocessor systems for drive control units
is already being practiced by the assignee of the instant
application.
[0081] In a still further embodiment, the control 42 of the
controller 14 as shown in FIG. 1 may be operative to control the
motor(s) 16,18 in a speed control loop. In this embodiment, the
control 42 would monitor the speed of the vehicle directly or
compute the speed of the vehicle from the speed of the motor and
control the power control stage 28,30 to generate a drive signal
34, 36 to operate the vehicle at a desired speed. One such drive
controller is, for example, the MKIV and the MKIVGB controllers
manufactured by the assignee of the instant application. A signal
may be communicated from control 42 to the mode controller 32 over
path 22, for example, so that the mode controller 32 may control
the operating mode of the booster circuit 11 based on whether or
not the drive signal is sufficient to operate the vehicle at the
desired speed.
[0082] When controlled in the transparent bypass mode, the booster
11 provides a voltage to the power stage 28,30 that is matching or
less than the voltage of the battery source. In this mode, the
power control stage 28,30 is capable of producing a drive signal up
to a maximum level, which is limited by the battery voltage, to
control the motor to operate the vehicle at the desired speed or a
certain maximum speed. The mode control 32 may sense as described
herein above that the drive signal is nearing its maximum and thus
insufficient to operate the vehicle at the desired speed, and
control the voltage booster circuit 11 between modes which can
increase the voltage supply to the power control stage.
[0083] However, if the control 42 determines that the current of
the drive signal is greater than a predetermined level, it may send
a signal over path 22, for example, to inhibit the mode control
circuit from altering the mode of operation of the booster circuit
11. Alternatively, it may withhold the signal representative of the
drive signal from the mode control 32 in which case, the mode
control 32 would have no basis for altering the operational mode of
the booster circuit. Additional protective circuits may be added
such as, for example, to the booster or controller circuit to
measure currents, temperatures and/or over-voltage directly.
[0084] Accordingly, the multi-mode motor controller 10 offers:
improved matching of load to power supply, enhanced dynamics range
for the power controller, negligible impact on efficiency, drive
comfort and other key parameters, in particular while using the
transparent bypass mode, and add-on solution, compatible with
existing drive power control devices.
[0085] While the present invention has been described herein above
in connection with a number of different embodiments, it is
understood that the invention should not be limited in any way,
shape or form by any single embodiment. Rather, the present
invention should be construed in breadth and broad scope in
accordance with the recitation of the claims appended hereto.
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